ASTM D7549-23

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D7549 − 23
Standard Test Method for
Evaluation of Heavy-Duty Engine Oils under High Output
Conditions—Caterpillar C13 Test Procedure
This standard is issued under the fixed designation D7549; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
Any properly equipped laboratory, without outside assistance, can use the test procedure described
in this test method. The ASTM Test Monitoring Center (TMC) provides calibration and an
assessment of the test results obtained on those oils by the laboratory. By this means the laboratory
will know whether its use of the test method gives results statistically similar to those obtained by
other laboratories. Furthermore, various agencies require that a laboratory utilizes the TMC services
in seeking qualification of oils against specifications. For example, the U.S. Army has such a
requirement in some of its engine oil specifications. Accordingly, this test method is written for those
laboratories that use the TMC services. Laboratories that choose not to use these services should
ignore those portions of the test method that refer to the TMC. Information letters issued periodically
by the TMC may modify this test method. In addition the TMC may issue supplementary memoranda
related to the test method.
ASTM International policy is to encourage the development of test procedures based on generic
equipment. It is recognized that there are occasions where critical/sole-source equipment has been
approved by the technical committee (surveillance panel/task force) and is required by the test
procedure. The technical committee that oversees the test procedure is encouraged to clearly identify
if the part is considered critical in the test procedure. If a part is deemed to be critical, ASTM
encourages alternative suppliers to be given the opportunity for consideration of supplying the critical
part/component providing they meet the approval process set forth by the technical committee.
An alternative supplier can start the process by initiating contact with the technical committee
(current chairs shown on ASTM TMC website). The supplier should advise on the details of the part
that is intended to be supplied. The technical committee will review the request and determine
feasibility of an alternative supplier for the requested replacement critical part. In the event that a
replacement critical part has been identified and proven equivalent, the sole-source supplier footnote
shall be removed from the test procedure.
1. Scope* performance with regard to piston deposit formation, piston
ring sticking and oil consumption control in a combustion
1.1 The test method covers a heavy-duty engine test proce-
environment designed to minimize exhaust emissions. This test
dure under high output conditions to evaluate engine oil
method is commonly referred to as the Caterpillar C13
Heavy-Duty Engine Oil Test.
This test method is under the jurisdiction of ASTM Committee D02 on
1.2 The values stated in SI units are to be regarded as
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
standard. No other units of measurement are included in this
Subcommittee D02.B0 on Automotive Lubricants.
standard.
Current edition approved July 1, 2023. Published July 2023. Originally published
in 2009. Last previous edition approved in 2021 as D7549 – 21. DOI: 10.1520/
1.2.1 Exceptions—Where there are no SI equivalent such as
D7549-23.
screw threads, National Pipe Treads (NPT), and tubing sizes.
The ASTM Test Monitoring Center will update changes in this test method by
means of Information Letters. This edition includes all information letters through
No. 23-1. Information Letters may be obtained by from the ASTM Test Monitoring Caterpillar Inc., Engine System Technology Development, PO Box 610,
Center, 203 Armstrong Drive, Freeport, PA 16229, Attention: Director. Mossville, IL 61552-0610.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D7549 − 23
1.3 This standard does not purport to address all of the D4739 Test Method for Base Number Determination by
safety concerns, if any, associated with its use. It is the Potentiometric Hydrochloric Acid Titration
responsibility of the user of this standard to establish appro- D5185 Test Method for Multielement Determination of
priate safety, health, and environmental practices and deter- Used and Unused Lubricating Oils and Base Oils by
mine the applicability of regulatory limitations prior to use. Inductively Coupled Plasma Atomic Emission Spectrom-
See Annex A1 for general safety precautions. etry (ICP-AES)
1.4 This international standard was developed in accor- D5186 Test Method for Determination of the Aromatic
dance with internationally recognized principles on standard- Content and Polynuclear Aromatic Content of Diesel
ization established in the Decision on Principles for the Fuels By Supercritical Fluid Chromatography
Development of International Standards, Guides and Recom- D5453 Test Method for Determination of Total Sulfur in
mendations issued by the World Trade Organization Technical Light Hydrocarbons, Spark Ignition Engine Fuel, Diesel
Barriers to Trade (TBT) Committee. Engine Fuel, and Engine Oil by Ultraviolet Fluorescence
D5967 Test Method for Evaluation of Diesel Engine Oils in
2. Referenced Documents
T-8 Diesel Engine
D6078 Test Method for Evaluating Lubricity of Diesel Fuels
2.1 ASTM Standards:
by the Scuffing Load Ball-on-Cylinder Lubricity Evalua-
D86 Test Method for Distillation of Petroleum Products and
tor (SLBOCLE) (Withdrawn 2021)
Liquid Fuels at Atmospheric Pressure
D6681 Test Method for Evaluation of Engine Oils in a High
D93 Test Methods for Flash Point by Pensky-Martens
Speed, Single-Cylinder Diesel Engine—Caterpillar 1P
Closed Cup Tester
Test Procedure
D97 Test Method for Pour Point of Petroleum Products
D6987/D6987M Test Method for Evaluation of Diesel En-
D130 Test Method for Corrosiveness to Copper from Petro-
gine Oils in T-10 Exhaust Gas Recirculation Diesel
leum Products by Copper Strip Test
Engine (Withdrawn 2022)
D235 Specification for Mineral Spirits (Petroleum Spirits)
E29 Practice for Using Significant Digits in Test Data to
(Hydrocarbon Dry Cleaning Solvent)
Determine Conformance with Specifications
D445 Test Method for Kinematic Viscosity of Transparent
E178 Practice for Dealing With Outlying Observations
and Opaque Liquids (and Calculation of Dynamic Viscos-
ity)
2.2 Other ASTM Document:
D482 Test Method for Ash from Petroleum Products ASTM Deposit Rating Manual 20 (formerly CRC Manual
D524 Test Method for Ramsbottom Carbon Residue of
20)
Petroleum Products
D613 Test Method for Cetane Number of Diesel Fuel Oil
3. Terminology
D664 Test Method for Acid Number of Petroleum Products
3.1 Definitions:
by Potentiometric Titration
3.1.1 blind reference oil, n—a reference oil, the identity of
D975 Specification for Diesel Fuel
which is unknown by the test facility.
D976 Test Method for Calculated Cetane Index of Distillate
3.1.1.1 Discussion—This is a coded reference oil that is
Fuels
submitted by a source independent of the test facility. D4175
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
3.1.2 blowby, n—in internal combustion engines, the com-
leum Products by Fluorescent Indicator Adsorption
bustion products and unburned air-and-fuel mixture that enter
D2274 Test Method for Oxidation Stability of Distillate Fuel
the crankcase. D4175
Oil (Accelerated Method)
D2622 Test Method for Sulfur in Petroleum Products by
3.1.3 calibrate, v—to determine the indication or output of a
Wavelength Dispersive X-ray Fluorescence Spectrometry
measuring device with respect to that of a standard. D4175
D2709 Test Method for Water and Sediment in Middle
3.1.4 heavy duty, adj—in internal combustion engine
Distillate Fuels by Centrifuge
operation, characterized by average speeds, power output, and
D3524 Test Method for Diesel Fuel Diluent in Used Diesel
internal temperatures that are close to the potential maximums.
Engine Oils by Gas Chromatography
D4175
D4052 Test Method for Density, Relative Density, and API
3.1.5 heavy-duty engine, n—in internal combustion engine
Gravity of Liquids by Digital Density Meter
types, one that is designed to allow operation continuous at or
D4175 Terminology Relating to Petroleum Products, Liquid
close to its peak output.
Fuels, and Lubricants
3.1.5.1 Discussion—This type of engine is typically in-
D4294 Test Method for Sulfur in Petroleum and Petroleum
stalled in large trucks and buses as well as farm, industrial, and
Products by Energy Dispersive X-ray Fluorescence Spec-
construction equipment. D4175
trometry
4 5
For referenced ASTM standards, visit the ASTM website, www.astm.org, or The last approved version of this historical standard is referenced on
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM www.astm.org.
Standards volume information, refer to the standard’s Document Summary page on For Stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
the ASTM website. ASTM International Customer Service at service@astm.org.
D7549 − 23
3.1.6 non-reference oil, n—any oil other than a reference oil, 3.3.16 OC—oil consumption
such as a research formulation, commercial oil, or candidate
3.3.17 P/N—part number
oil. D4175
3.3.18 QI—quality index
3.1.7 non-standard test, n—a test that is not conducted in
3.3.19 RPTGC—reference relative top groove carbon pro-
conformance with the requirements in the standard test
file
method, such running on an uncalibrated test stand, using
3.3.20 SDTGCO—standard deviation top groove carbon
different test equipment, applying different equipment assem-
outlier
bly procedures, or using modified operating conditions. D4175
3.3.21 TGC—top groove carbon
3.1.8 reference oil, n—an oil of known performance
characteristics, used as a basis for comparison. 3.3.22 ULSD—ultra low sulfur diesel
3.1.8.1 Discussion—Reference oils are used to calibrate
4. Summary of Test Method
testing facilities, to compare the performance of other oils, or
4.1 This test method uses a Caterpillar production C13
to evaluate other materials (such as seals) that interact with
diesel engine (see Annex A3 for ordering information and list
oils. D4175
of engine build parts). Test operation includes a 60 min engine
3.1.9 test oil, n—any oil subjected to evaluation in an
warm-up and break-in, followed by a 4 h cool down and valve
established procedure.
lash adjustment. After the valve lash adjustment and any other
3.1.9.1 Discussion—It can be any oil selected by the labo-
needed adjustments, a 500 h test is begun. The engine is
ratory conducting the test. It could be an experimental product
operated under steady-state, rated-power conditions known to
or a commercially available oil. Often, it is an oil that is a
generate excessive piston deposits or oil consumption or both
candidate for approval against engine oil specifications (such
in field service. Report the total engine oil consumption as the
as manufacturers’ or military specifications, and so forth).
sum of the measured volumes in 50 h increments.
D4175
4.2 Equip the test stand with the appropriate instrumentation
3.1.10 wear, n—the loss of material from a surface, gener-
to control engine speed, fuel flow, and other operating param-
ally occurring between two surfaces in relative motion, and
eters.
resulting from mechanical or chemical action or a combination
4.3 Determine the engine oil performance by assessing
of both.
piston deposits and ring sticking, and oil consumption.
3.2 Definitions of Terms Specific to This Standard:
4.3.1 Prior to each test, clean and assemble the engine with
3.2.1 overhead, n—in internal combustion engines, the
new cylinder liners, pistons, piston rings, bearings and certain
components of the valve train located in or above the cylinder
valve train components. All aspects of the assembly are
head.
specified. After the test, dismantle the engine and examine and
3.2.2 tote, n—a container, smaller in capacity than a gallon.
rate the parts.
3.2.3 valve train, n—in internal combustion engines, the 4.3.2 A sample of engine oil is removed and an oil addition
series of components, such as valves, crossheads, rocker arms, is made at the end of each 50 h period. The volume of the oil
push rods and camshaft that open and close the intake and addition is the sum of the volume of sample plus the volume of
exhaust valves. oil consumed by the engine.
3.3 Abbreviations and Acronyms:
5. Significance and Use
3.3.1 ACERT—Advanced Combustion Emission Reduction
5.1 This test method assesses the performance of an engine
Technology
oil with respect to control of piston deposits and maintenance
3.3.2 ATGC—average top groove carbon
of oil consumption under heavy-duty operating conditions
selected to accelerate deposit formation in a turbocharged,
3.3.3 ATGCO—average top groove carbon offset
intercooled four-stroke-cycle diesel engine equipped with a
3.3.4 CARB—California Air Resources Board
combustion system that minimizes federally controlled exhaust
3.3.5 CAT—acronym for Caterpillar
gas emissions.
3.3.6 CRC—Coordinating Research Council
5.2 The results from this test method may be compared
3.3.7 DACA—Data Acquisition and Control Automation
against specification requirements to ascertain acceptance.
3.3.8 ECM—engine control module
5.3 The design of the test engine used in this test method is
representative of many, but not all, diesel engines. This factor,
3.3.9 EOT—end of test
along with the accelerated operating conditions, needs to be
3.3.10 HC—heavy carbon
considered when comparing test results against specification
3.3.11 IMP—intake manifold pressure
requirements.
3.3.12 LC—light carbon
6. Apparatus
3.3.13 LTMS—Lubricant Test Monitoring System
6.1 Test Engine Configuration:
3.3.14 MC—medium carbon
6.1.1 Test Engine—The test engine is a production 2004
3.3.15 NPT—National Pipe Thread Caterpillar 320 kW C13 engine, designed for heavy duty
D7549 − 23
on-highway truck use. It is an electronically controlled, 6.2.2 Intake Air System—With the exception of the air filter
turbocharged, after-cooled, direct injected, six cylinder diesel and intake air tube, the intake air system is not specified. See
engine with an in-block camshaft and a four-valve per cylinder Fig. X1.1 of a typical configuration. Use a suitable air filter.
arrangement. The engine uses Caterpillar’s ACERT technology Install the intake air tube (Fig. A4.6) at the intake of the
featuring multiple injections per cycle and inlet valve actuation
turbocharger compressor. The intake air tube is a minimum
control. It features a 2004 US EPA emissions configuration 305 mm of straight, nominal 102 mm diameter tubing. The
with electronic control of fuel metering, fuel injection timing
system configuration upstream of the air tube is not specified.
and inlet valve actuation timing. Critical parts that can affect
NOTE 1—Difficulty in achieving or maintaining intake manifold pres-
piston deposit formation are specified for oil test engine use.
sure or intake manifold temperature, or both, may be indicative of
See Annex A3 for source of the test engine and critical and
insufficient or excessive restriction.
non-critical parts.
6.2.3 Charge Air Cooler—In addition to the Caterpillar
6.1.2 Oil Heat Exchanger and Oil Heat System—Replace
supplied charge air cooler which is engine mounted, use
the standard Caterpillar oil heat exchanger core with a stainless
another cooler to simulate the air-to-air charge air cooler used
steal core, Caterpillar P/N 1Y-4026. Additionally install a
in most field applications. A Modine (P/N 1A012865) cooler
remotely mounted heat exchanger. Control the oil temperature
has been found suitable for this use. See A2.1 for instructions
with a dedicated cooling loop and control system which is
on obtaining this cooler. Alternatively, other charge air coolers
separate from the engine coolant (see Annex A12). Ensure that
may be used with the following limitations: (1) the cooler shall
the oil cooler bypass valve is blocked closed.
provide sufficient cooling capacity to control inlet manifold
6.1.3 Oil Pan Modification—Modify the oil pan as shown in
temperatures in the range specified elsewhere in this test
A4.1.
method; (2) the boost air pressure drop across the cooler not
6.1.4 Engine Control Module (ECM)—The ECM defines the
exceed 15 kPa; and (3) the cooler is equipped with a drain
desired engine fuel timing and quantity. It also limits maximum
system to remove condensate continuously from the boost air
engine speed and power. Caterpillar electronic governors are
cooler outlet side. Remove the coolant diverter valve dia-
designed to maintain a speed indicated by the throttle position
phragm for the Caterpillar supplied charge air cooler.
signal. Speed variation drives fuel demand (rack). Rack and
6.2.4 Exhaust System—Install the exhaust tube, see Fig.
engine speed are input to the injection duration and timing
A4.7, at the discharge flange of the turbocharger turbine
maps to determine duration and timing commands for the fuel
injectors. Obtain special oil test engine control software housing. The piping downstream of the exhaust tube is
required, but not specified. Provide a method to control exhaust
(module P/N 250-6775) for correct maps. Contact the Cater-
pillar oil test representative through TMC for installation of pressure.
this software. Use the Caterpillar engine technician (ET)
6.2.5 Fuel System—The fuel supply and filtration system is
service software package, version 2004B or later, to monitor
not specified. See Fig. X1.2 for a typical configuration.
engine parameters, flash software, and to change power and
Determine the fuel consumption rate by measuring the rate of
injector trim values. Use the full dealer version purchased from
fresh fuel flowing into the day tank. Provide a method to
a Caterpillar dealer with a yearly subscription.
control fuel temperature. Return the excess fuel from the
6.1.5 Crankshaft Position Sensor—Sense the crankshaft
engine into the day tank.
position using a primary sensor at the crankshaft gear and as
6.2.6 Coolant System—The system configuration is not
secondary sensor at the camshaft gear. The secondary sensor
specified. See Fig. X1.3 showing a typical configuration
provides position information during cranking and in the event
consisting of a non-ferrous core heat exchanger, a reservoir
of a primary sensor position failure. Calibrate the engine
(expansion tank) and a temperature control valve. Pressurize
control software before starting the timed test operation.
the system by regulating air pressure at the top of the expansion
6.1.6 Air Compressor—Do not use the engine-mounted air
tank. Ensure the system has a sight glass to detect air
compressor for this test method. Remove the air compressor
entrapment.
and install a block-off plate kit in its place (P/N 227-2574 cover
6.2.6.1 System volume is not specified. Avoid a very large
group and P/N 223-3873, plug group) (Fig. A4.5 or equiva-
volume as it may increase the time required for the engine
lent).
coolant to reach operating temperatures.
6.1.6.1 Modify the turbocharger waste-gate for manual
6.2.7 Pressurized Oil Fill System—The oil fill system is not
control by replacing the supplied pressure control with a
specified. A typical system includes an electric pump, a 50 L
manual linkage. See Figs. A4.21-A4.23.
reservoir, and a transfer hose. Fig. A4.24 shows the location of
6.2 Test Stand Configuration:
the pressurized oil fill system.
6.2.1 Engine Mounting—Install the engine so that it is
6.2.8 External Oil System—Configure the oil system ac-
upright and the crankshaft is horizontal.
cording to Fig. A5.1. The capacity of the oil reservoir is (10 to
6.2.1.1 Configure the engine mounting hardware to mini-
13) L. Ensure that the oil return is drawn from the bottom of
mize block distortion when the engine is fastened to the
the oil reservoir Fig. A4.9. Use Viking Pump Model No.
mounts. Excessive block distortion may influence test results.
SG053514. Locate the external oil pumps at an elevation that
is below the pump supply fitting on the oil pan. The nominal oil
pump motor speed is 1725 rpm. Figs. A4.1-A4.4 show the
Trademark of Caterpillar Inc., 100 North East Adams St., Peoria, IL 61629. pump supply and return port locations.
D7549 − 23
A
TABLE 1 Maximum Allowable System Time Responses TABLE 2 Cat ELC Coolant Concentrate and
Premix 50/50 Options
Measurement Time Response
B
Tote,
Container Size 3.8 L 19 L 208 L
Speed 2.0 s
275 g
Temperature 3.0 s
Concentrate P/N 119-5150 . 136-3707 .
Pressure 3.0 s
Premixed 50/50 P/N 101-2844 129-2151 101-2845 222-1534
Flow 45.0 s
A
Trademark of Caterpillar Inc., 100 North East Adams St., Peoria, IL 61629.
B
A small container.
6.2.8.1 Oil Sample Valve Location—Locate the oil sample
valve on the return line from the external oil system to the
7.3 Engine Coolant—Prepare the engine coolant by mixing
engine, and as close as possible to the return pump see Fig.
50 % volume of mineral-free water with 50 % volume of
A4.9 and Fig. A5.1.
Caterpillar brand coolant concentrate (As an option, pre-mixed
6.2.8.2 Unacceptable Oil System Materials—Do not use
coolant is available and may be used directly).
brass or copper fittings because they can adversely influence oil
7.3.1 Table 2 shows Caterpillar part numbers for several
wear metal analyses in the external oil system.
sized containers of concentrate or premixed coolant.
6.2.9 Crankcase Aspiration—Vent the blowby gas at the
7.3.2 The mineral-free water shall have a mineral content
blowby filter housing located at the left front side of the
not exceeding 34.4 mg/kg of total dissolved solids.
cylinder head cover (Fig. A4.10). Use crankcase breather P/N
7.3.3 The coolant mixture may be used for 6 test starts or up
9Y-4357. Use breather spacer P/N 221-3934 or equivalent
to 3400 h. The mixture shall remain at a 50/50 ratio during the
20 mm thick plate with a fully open center. Use a P/N 9Y-1758
course of the test. Verify by using either Caterpillar testers
gasket on each side of the spacer.
5P3514 or 5P0957 or an equivalent tester. Keep the coolant
6.2.10 Blowby Rate—See the general configuration of this
mixture free from contamination.
system in Fig. A4.10. The minimum internal volume of the
7.3.4 Keep the total solids below 5000 mg/kg.
blowby canister is 26.5 L. The inside diameter of the pipe
7.3.5 Maintain a correct additive level. Verify by checking
connecting the breather outlet to the blowby canister is 32 mm.
the coolant using Caterpillar test kit P/N 8T5296.
Incline the pipe downward to the canister. The hose connecting
7.4 Solvents and Cleaners Required: (Warning—Use ad-
the blowby canister to the flow rate measuring device is not
equate safety precautions with all solvents and cleaners.)
specified but shall match closely to the inlet of the device. The
7.4.1 Solvent—Use mineral spirits meeting Specification
flow rate measurement device is not specified. The J-TEC
8 D235, Type II, Class C requirements for aromatic content (0 %
Associates, Inc. Model No. YF563C does give satisfactory
to 2 % by vol), flash point (61 °C, min), and color (not darker
results under the conditions specified in this test method.
than +25 on Saybolt Scale or 25 on Pt-Co Scale). Obtain a
6.3 System Time Responses—The maximum allowable sys-
Certificate of Analysis for each batch of solvent from the
tem time responses are shown in Table 1. Determine system
supplier. (Warning—Combustible. Health Hazard.)
time responses in accordance with the Data Acquisition and
7.4.2 Pentane—Used for rinsing and cleaning components
Control Automation II (DACA II) Task Force Report.
before measurement. (Warning—Flammable. Health hazard.)
7.4.3 Heptane—Used for rinsing and cleaning components
6.4 Oil Sample Containers—Preferably use high-density
before measurement. (Warning—Flammable. Health hazard.)
polyethylene containers for oil samples. (Warning—Avoid
7.4.4 WD-40 —Used for rinsing and cleaning components
using glass containers which may break and cause injury or
before measurement. (Warning—Flammable. Health hazard.)
exposure to hazardous materials.)
7.4.5 Degreasing Solvent—EnSolv , a proprietary n-propyl
7. Engine Liquids and Cleaning Solvent
bromide based solvent that can be used for cleaning the second
rings. (Warning—Health hazard.)
7.1 Test Oil—Approximately 150 L of test oil is required to
complete the test.
8. Preparation of Apparatus
7.2 Test Fuel—Approximately 45 000 L of Chevron Philips
8.1 Cleaning of Parts:
PC-10 ultra low sulfur diesel fuel is required to complete the
test. Fuel property tolerances are shown in Annex A6.
WD-40 is a registered trademark of the WD-40 Company 9715 Businesspark
Ave., San Diego, CA 92131 USA, http://www.wd40.com. WD-40 is available from
The sole source of supply of the apparatus known to the committee at this time local retailers. The sole source of supply of this product known to the committee at
is J-TEC Associates, Inc., 5005 Blairs Forest Lane NE, Suite L, Cedar Rapids, IA this time is the WD-40 Company. If you are aware of alternative suppliers, please
52402, www.j-tecassociates.com. If you are aware of alternative suppliers, please provide this information to ASTM International Headquarters. Your comments will
provide this information to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the responsible technical committee,
receive careful consideration at a meeting of the responsible technical committee, which you may attend.
which you may attend. EnSolv is a registered trademark of and is available from Enviro Tech
The sole source of supply of the apparatus known to the committee at this time International, Inc., 2525 West LeMoyne Ave., Melrose Park, IL 60160, http://
is Chevron Phillips Chemical Company LP, 10001 Six Pines Drive, Suite 4036B, www.ensolv.com. The sole source of supply of the EnSolv known to the committee
The Woodlands, TX 77387-4910, www.cpchem.com. If you are aware of alternative at this time is Enviro Tech International, Inc. If you are aware of alternative
suppliers, please provide this information to ASTM International Headquarters. suppliers, please provide this information to ASTM International Headquarters.
Your comments will receive careful consideration at a meeting of the responsible Your comments will receive careful consideration at a meeting of the responsible
1 1
technical committee, which you may attend. technical committee, which you may attend.
D7549 − 23
8.1.1 General—Preparation of test engine components spe- 8.2.6 Piston Cooling Tubes—Target the piston cooling
cific to the Caterpillar C13 test are indicated in this section. tubes. Contact TMC for directions.
Use the Caterpillar Service Manual Form SEN R 9700 8.2.7 New Parts—The following new parts are included in
(Annex A7) for the preparation of other components (except the Engine Build Parts List. They are not reusable, except as
for the piston second ring—see 8.2.7). Take precautions to noted in 10.3.3. Clean the parts prior to use. For piston second
protect rusting of iron components. Use of an engine parts rings and cylinder liners, clean with WD-40 and wipe with a
washer followed by a solvent wash is permitted. clean rag. After wiping the parts, rinse them with pentane or
8.1.2 Engine Block—Disassemble the engine, including re- heptane. Finally, coat the second rings and cylinder liners with
moval of the crankshaft, camshaft, piston cooling tubes, oil build-up oil. During a test, a replacement of any of the new
pump, and oil gallery plugs. Thoroughly clean the surfaces and parts listed below will invalidate the test.
oil passages (galleries). Use a nylon brush to clean the oil 8.2.7.1 Pistons.
passages. Removal of camshaft bearings is optional. 8.2.7.2 Piston rings (top, second and oil).
8.1.3 Cylinder Head, Intake System and Duct—Disassemble 8.2.7.3 Cylinder liners.
and clean these components before each test. Scrub with a 8.2.7.4 Valves (intake, exhaust).
nylon brush and solvent. Use of an engine parts washer 8.2.7.5 Valve guides.
followed by a solvent wash is permitted. 8.2.7.6 Valve seats.
8.1.4 Rocker Cover and Oil Pan—Clean the Rocker Cover 8.2.7.7 Connecting rod bearings, main bearings and thrust
and Oil Pan. Use a nylon brush, as necessary, to remove plate.
deposits.
8.3 Operational Measurements:
8.1.5 External Oil System—Flush the internal surfaces of
8.3.1 Units and Formats—See Annex A8.
the oil lines and the external reservoir with solvent. Repeat
8.3.2 Instrumentation Calibration:
until the solvent drains cleanly. Flush the solvent through the
8.3.2.1 Fuel Consumption Rate Measurement—Calibrate
oil pumps until the solvent drains cleanly, then air dry.
the fuel consumption rate measurement system before each
8.1.6 High Pressure Turbocharger—Carefully remove the
reference oil test sequence and within six months after comple-
turbine housing from the turbocharger and clean the waste-gate
tion of the last successful calibration test. Temperature-
valve with solvent and a soft wire brush.
compensate volumetric systems, and calibrate them against a
8.1.7 Cam Follower Assembly—Take the cam follower as-
standard mass flow device. The flowmeter on the test stand
sembly apart and inspect the bushings and pins. Replace the
shall agree within 0.2 % of the calibration standard, that
parts as necessary.
standard itself being calibrated against a national standard.
8.2 Engine Assembly: 8.3.2.2 Temperature Measurement Calibration—Calibrate
8.2.1 General—Except as noted in this section, use the the temperature measurement systems before each reference oil
procedures described in the Caterpillar Service Manual Form test sequence and within six months after completion of the last
SEN R 9700 (Annex A7). Assemble the engine with the successful calibration test. Each temperature measurement
components shown in the Engine Build Parts List (Annex A3). system shall agree within 60.5 °C of the laboratory calibration
8.2.2 Parts Reuse and Replacement—Reuse engine standard, that standard itself being calibrated against a national
components, except as noted in 8.2.7, and provided that they standard.
meet production tolerances as described in the Caterpillar 8.3.2.3 Pressure Measurement Calibration—Calibrate the
Service Manual. pressure measurement systems before each reference oil test
8.2.3 Build-up Oils—For the head, main caps, and rod bolts, sequence and within six months after completion of the last
use Exxon Mobil 600N engine oil as the build-up oil. For the successful calibration test. Confirm the calibration standard
rest of the engine build, use Mobil EF-411 engine oil or test against a national standard.
oil to lubricate the parts. If test oil is used, the engine build is 8.3.3 Temperature Measurement Locations:
valid only for the respective test oil. 8.3.3.1 General—See Table A14.1. The measurement
8.2.4 Coolant Thermostat—Lock the engine coolant ther- equipment is not specified. Install the sensors such that the tip
mostat open. is located midstream of the flow unless otherwise indicated.
8.2.5 Fuel Injectors—Use P/N 239-4908 fuel injectors. If The accuracy and measurement of the temperature measure-
fuel injectors are reused, exercise caution to avoid mechanical ment sensors and the complete measurement system shall
damage to or contamination of the nozzles. Dedicate the follow the guidelines in ASTM Research Report RR:D02-
injectors to a particular cylinder. Install the injectors according 1218.
to the method described in Caterpillar Service Manual Form 8.3.3.2 Coolant Out Temperature—Install the sensor in the
SENR9700 (Annex A7). Use Mobil EF-411 engine oil as the fitting on the thermostat housing (Fig. A4.12).
build-up oil for the injector o-rings. 8.3.3.3 Coolant In Temperature—Install the sensor on the
right side of the coolant pump intake housing at the 1-in. NPT
port (Fig. A4.13).
Available from a Caterpillar parts distributor.
The sole source of supply of the apparatus known to the committee at this time
is ExxonMobil Corporation, 3225 Gallows Road, Fairfax, VA 22037, www.exxon-
mobil.com. If you are aware of alternative suppliers, please provide this information Supporting data have been filed at ASTM International Headquarters and may
to ASTM International Headquarters. Your comments will receive careful consid- be obtained by requesting Research Report RR:D02-1218. Contact ASTM Customer
eration at a meeting of the responsible technical committee, which you may attend. Service at service@astm.org.
D7549 − 23
8.3.3.4 Fuel In Temperature—Install the sensor in the fuel 8.3.4.11 Additional Pressures—It is permissible to measure
pump inlet fitting (Fig. A4.15). any additional pressures that may be useful for test operation or
engine diagnostics.
8.3.3.5 Oil Gallery Temperature—Install the sensor at the
⁄4 in. NPT female boss on the right rear of the engine (Fig.
NOTE 3—See Fig. A4.19 and Fig. A4.20 for additional instrument
A4.14).
placement information.
8.3.3.6 Intake Air Temperature—Install the sensor in the
8.3.5 Flow Rate Measurement Locations:
inlet air tube 127 mm upstream of the compressor connection
8.3.5.1 General—The equipment for the blowby rate and
(Fig. A4.6).
fuel rate measurements is not specified. Follow the guidelines
8.3.3.7 Intake Manifold Temperature—Install the sensor at
in ASTM Research Report RR:D02-1218 for the accuracy
the ⁄8 in. NPT female boss on the outside radius of the inlet
and resolution of the flow rate measurement system.
manifold elbow (Fig. A4.16).
8.3.5.2 Blowby—The device used to measure the blowby
8.3.3.8 Exhaust Temperature—Install the sensor in the ex-
flow rate is not specified. See 6.2.10 for blowby measurement
haust tube (Fig. A4.7).
system configuration details.
8.3.3.9 Additional Temperatures—It is permissible to mea-
8.3.5.3 Fuel Flow—Determine the fuel consumption rate by
sure any additional temperatures that may be useful for test
measuring the fuel flowing to the day tank (Fig. X1.2).
operation or engine diagnostics.
8.3.5.4 Coolant Flow—Coolant flow rate measurement is
NOTE 2—Additional exhaust sensor locations, at the exhaust ports and
not a test requirement, but may be useful for diagnostic
pre-turbine (front and rear), are recommended. The detection of changes
purposes. The design and use of a coolant flow measuring
in exhaust temperatures is an important diagnostic feature.
system is optional.
8.3.4 Pressure Measurement Locations:
8.3.6 Humidity Measurement—Measure intake air humidity
8.3.4.1 General—The measurement equipment is not speci-
anywhere in the air intake system between air conditioning and
fied. Follow the guidelines in ASTM Research Report
the turbo inlet.
RR:D02-1218 for the accuracy and resolution of the pressure
measurement sensors and the complete measurement system. If
9. Engine/Stand Calibration and Non-Reference Oil Tests
the laboratory has problems with condensation forming in the
9.1 General—Calibrate the test stand by conducting a test
pressure lines, install a condensation trap at the lowest eleva-
with a blind reference oil. Submit the results to the TMC for
tion of the tubing between the pressure measurement location
determination of acceptance according to the Lubricant Test
and the final pressure sensor for crankcase pressure, intake air
Monitoring System (LTMS).
pressure, and exhaust pressure. Route the tubing to avoid
intermediate loops or low spots before and after the conden-
9.2 New Laboratories and New Test Stands:
sation trap. 9.2.1 New Laboratory—A new laboratory is any laboratory
8.3.4.2 Oil Gallery Pressure—Measure the pressure at the that has never previously calibrated a test stand by this test
⁄4 in. NPT fitting on the right rear of the engine (Fig. A4.14). method.
8.3.4.3 Oil Filter Inlet Pressure—Measure the pressure at 9.2.2 New Test Stand—A new test stand is a test cell and
the plug located on the inlet side of the oil filter assembly (Fig.
support hardware that has never previously been calibrated by
A4.8). this test method. Perform a calibration (9.2.3) to introduce a
8.3.4.4 Inlet Manifold Pressure—Measure the pressure at new test stand.
the ⁄4 in. NPT port on the outside radius of the inlet manifold
9.2.3 New Test Stand Calibration—Calibrate a new test
elbow (Fig. A4.16). stand in accordance with the LTMS.
8.3.4.5 Crankcase Pressure—Measure the pressure by in-
9.3 Stand Calibration Period—The calibration period is 12
stalling a bulkhead fitting in the valve cover, top-front (Fig.
operationally valid (Annex A11) non-reference oil tests or
A4.11).
12 months, whichever comes first, from the EOT date of the
8.3.4.6 Intake Air Pressure—Measure the pressure at a wall
last acceptable reference oil test.
tap on the intake air tube 153 mm upstream of the compressor
9.4 Stand Modification and Calibration Status—Stand cali-
connection (Fig. A4.6).
bration status will be invalidated by conducting any non-
8.3.4.7 Exhaust Pressure—Measure the pressure on the
standard test or modification of the test and control systems, or
exhaust tube (Fig. A4.7).
both. A non-standard test is any test conducted under a
8.3.4.8 Fuel Pressure—Measure the pressure at the fuel
modified procedure, non-procedural hardware, controller set-
filter head (Fig. A4.25).
point modifications, or any combination thereof. If changes are
8.3.4.9 Coolant Pressure—Measure the pressure on top of
contemplated, contact the TMC beforehand to ascertain the
the expansion tank (Fig. X1.3).
effect on the calibration status.
8.3.4.10 Intercooler Delta Pressure—Measure the pressure
9.5 Test Numbering System:
drop across the intercooler. Measure the intercooler inlet
pressure at the elbow outlet of the CAT charge air cooler (Fig. 9.5.1 General—The test number has two parts, X and Y. X
A4.19). Use the intake manifold pressure (8.3.4.4) as the represents the test stand number and Y represents the sequen-
intercooler outlet pressure. The intercooler delta pressure is the tial test stand run number. For example 27-15 indicates test
difference between the intercooler outlet pressure and the stand number 27 and test stand run number 15. The test stand
intercooler inlet pressure. run number, Y will increase sequentially by one for each test
D7549 − 23
start (reference oil or non-reference oil). A letter suffix may intervals between reference oil tests. These extensions shall not
also be necessary (see 9.5.2). exceed one regular calibration period.
9.5.2 Reference Oil Tests—A reference oil test conducted
9.10.3 Reference Oil Test Data Flow—To ensure continuous
subsequent to an unacceptable reference oil test shall include a severity and precision monitoring, calibration tests are con-
letter suffix after Y. The letter suffix shall begin with A and
ducted periodically throughout the year. There may be occa-
incremented alphabetically until acceptable reference oil test is sions when laboratories conduct a large portion of calibration
completed. For example, if two consecutive unacceptable
tests in a short period of time. This could result in an
reference oil tests were conducted and the first number was unacceptably large time frame when very few calibration tests
27-15, the second test number would be 27-16A. A third
are conducted. The TMC can shorten or extend calibration
calibration attempt would have the test number 27-17B. If the periods as needed to provide a consistent flow of reference oil
third test were acceptable, then 27-17B would identify the
test data. Adjustments to calibration periods are made such that
reference oil test in the test report. laboratories incur no net loss (or gain) in calibration status.
9.5.3 Non-Reference Oil Tests—Add no letter suffix to Y for
9.10.4 Special Use of the Reference Oil Calibration
aborted or operationally invalid non-reference oil tests. System—The surveillance panel has the option to use the
reference oil system to evaluate changes that have potential
9.6 Reference Oil Test Acceptance—Determine reference oil
6 impact on test severity and precision. This option is only taken
test acceptance in accordance with the LTMS.
when a program of donated tests is not feasible. The surveil-
9.7 Reference Oil Accountability:
lance panel and the TMC shall develop a detailed plan for the
9.7.1 Keep full accounts of the identification and quantities
test program. This plan requires all reference oil tests in the
of all reference oils used. With the exception of the oil analyses
program to be completed as close to the same time as possible,
required in 11.3, perform no chemical or physical analyses on
so that no laboratory or stand calibration is left in an exces-
reference oils without written permission from the TMC. In
sively long pending status. In order to obtain the integrity of
such an event, include the written confirmation and the
the reference oil monitoring system each reference oil test is
analytical results generated in the reference oil test report.
conducted so as to be interpretable for stand calibration. To
9.7.2 Retain used reference oil samples for 90 days from the
facilitate the required test scheduling, the surveillance panel
EOT date.
may direct the TMC to lengthen and shorten reference oil
9.8 Non-Reference Oil Tests: Last Start Date—When run- calibration periods within laboratories such that the laborato-
ning a non-reference oil test during the calibration period; ries incur no net loss (or gain) in calibration status.
crank the engine prior to the expiration of the calibration period
9.11 Calibration of Piston and Ring Deposit Raters—Each
(9.3).
calendar year, each laboratory shall send at least one Heavy
9.9 Donated Reference Oil Test Programs—The surveil- Duty Diesel Rater to the ASTM Standardized Testing Deposit
lance panel is charged with maintaining effective reference oil
Rating Workshop. Each rater shall rate a minimum of six diesel
test severity and precision monitoring. During times of new pistons and one set of C13 rings. If this schedule is not suitable
parts introductions, new or re-blended reference oil additions, to a particular rater or test laboratory, then make alternative
and procedural revisions, it may be necessary to evaluate the arrangements as soon as possible to have the rater calibrated.
possible effects on severity and precision levels. The surveil-
lance panel may choose to conduct a program of donated 10. Procedure
reference oil tests in those laboratories participating in the
10.1 Engine Installation and Stand Connections—Install the
monitoring system to quantify the effect of a particular change
test engine on the stand and connect the engine to the stand
on severity and precision. Typically the surveillance panel
support equipment.
requests its panel members to volunteer enough reference oil
10.2 Coolant System Fill—Fill the cooling system with
test results to create a robust data set. Broad laboratory
pre-diluted Caterpillar Extended Life Coolant (see 7.3 for part
participation is needed to provide a representative sampling of
numbers and available container sizes). The coolant for non-
the industry. To ensure the quality of the data obtained, donated
reference oil tests may be reused provided the level of
tests are conducted on calibrated test stands. The surveillance
inhibitors is within specification requirements. Use new cool-
panel shall arrange an appropriate number of donated tests and
ant for each reference oil test. Pressurize the cooling system as
ensure completion of the test program in a timely manner.
required by the specification and check for leaks prior to
9.10 Adjustment to Reference Oil Calibration Periods:
adding the test oil.
9.10.1 Procedural Deviations—On occasions when a labo-
10.3 Oil Fill for Break-in and Test:
ratory becomes aware of a significant deviation from the test
10.3.1 Install a new Caterpillar 1R-1808 oil filter.
method, such as
...